Installation & Service Manual - Rex Materials Group

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Introduction and Welcome Thank you for choosing the Rex Thermal Control Solution (Rex TCS) for the temperature control needs on your Plastic Injection Molding or Extrusion machines. Rex TCS engineers have designed the Rex TCS Barrel Heaters to provide the latest and most efficient barrel temperature control technology for users seeking to meet the following performance criteria: Energy Savings - The Rex TCS heaters release high radiant energy directly into the barrel from exposed elements to maximize the heat transfer rate. Exposure of nearly the entire barrel surface to direct heat increases efficiency. The elements are captured in and protected by a high temperature ceramic insulating jacket which assures that the heat is contained and directed to the barrel, rather than heating the work area. The result is dramatically reduced energy usage in the range of 30-70%. Faster Thermal Response Time - Traditional barrel heaters must heat themselves before they begin to conduct heat into the barrel. They also retain considerable residual heat. This results in considerable lag time before the heat actually affects the barrel. The exposed elements of the Rex TCS heaters transfer heat immediately into the barrel providing much faster heat up and quicker response times. Better Temperature Control - The Rex TCS System’s direct radiant heating results in faster response to changing barrel conditions. This reduces set-point overshoot, resulting in much tighter barrel temperature control (typically better than + 1.0 degree F). This improvement can result in tighter dimensional control and, thereby, better product quality and less scrap. Improved Safety and Ergonomics - The Rex TCS heater elements are encased in a high temperature ceramic insulation which stays relatively cool compared to all other types of heaters, virtually eliminating the chance of burns. The excellent insulation also greatly reduces the ambient heat around the barrel. Therefore, the Rex TCS System contributes to a safer, more comfortable work environment. Long Life – Rex TCS heaters are designed to provide exceptionally long service life. This greatly reduces the ongoing replacement cost normally associated with standard barrel heaters. Quick and Easy Replacement - Rex TCS heaters are modular for fast and easy installation and replacement. 4
About This Guide This manual will 1) help you plan and prepare for implementing your Rex TCS System, 2) guide you through the installation procedure, 3) introduce you to the principles of its operation, and 4) describe the maintenance, troubleshooting and repair practices used to achieve optimum performance from your Rex TCS System. It is not intended to serve as a comprehensive training program. However, it does provide detailed, easy-to-understand instructions. If you have any questions that are not addressed by this guide, please consult your Rex TCS Sales Representative, or Rex TCS Technical Support at the numbers listed below. Safety Rex TCS Technical Support: Telephone: 1-517-223-3787 Fax: 1-517-223-6822 E-Mail: tcsinfo@rematerials.com Internet: www.rexmaterials.com Safety is a primary consideration in the design of Rex TCS Systems. Safety must also be a priority in its use. This manual provides guidelines and procedures to properly operate and maintain your Rex TCS System. It contains warnings and cautions that must be followed to reduce the risk of personal injury or damage to the equipment. However, due to the unique nature of each facility, it is impossible to foresee all of the potential hazards associated with its use. Your company is solely responsible for determining the adequacy of these recommendations and providing suitable safety instructions for your facility. Carefully read and understand this entire document. This important information will maximize safety, heater performance, efficiency and system life. All heating elements inherently pose burn, fire and electrical shock hazards. These can result in injury to personnel or damage to equipment. Care should always be exercised during installation and use. Do not install heaters in areas where combustible gas, vapor or dust is present. Only instructed or skilled persons shall be entrusted with the maintenance work of electro heat installations. No maintenance work shall be carried out with equipment live. Special arrangements 5
Page 1 and 2: Thermal Control Solution Installati
Page 3: Introduction Section One Introducti
Page 7 and 8: Equipment Overview Rex TCS Systems
Page 9 and 10: Installation & Assembly Section Two
Page 11 and 12: tuning controllers is recommended t
Page 13 and 14: Removing Packaging and Handling You
Page 15 and 16: Rex TCS Heater Assembly Installatio
Page 17 and 18: 5. 17 No terminals on the back side
Page 19 and 20: 9. B Measure dimension B from edge
Page 21 and 22: SINGLE ZONE 2 HALF HEATERS IN SERIE
Page 23 and 24: CERAMIC CAP CERAMIC COVER NUT LOCK
Page 25 and 26: Cut the Teflon cover flap as needed
Page 27 and 28: Operation Overview Before applying
Page 29 and 30: Documenting Savings and Performance
Page 31 and 32: Barrel Overheating If the zone temp
Page 33: How to Order Spare Parts The Rex TC

Installation & Service Manual - Rex Materials Group

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